Milling square cutouts is one of the most-feared tasks in box construction. There are some wonderful router systems available now – the best-known one is the Geat SDS-3. In fact, its success inspired a specialty manufacturer to integrate my beloved tool into his product range and to let hobbyists use it in exchange for a hefty payment. Less convenient but just as easy to use is my MPX-18, which cost me about €2.50.

Two 25 x 30 cm multiplex boards, 6 mm thick, form the basis for my routing template for square cutouts. To be on the safe side, I used twice as much wood as I needed. I’d rather not say what the real reason was.﻿

A pencil marking that I made 7 cm away from the long edge tells me...﻿

where to roll on the wood glue.﻿

After a short drying time, I was able to cut four small double boards that were 7 cm wide. That also explains my constant mentioning of the 7 cm edges.﻿

Two wood scraps cut to size and two small clamps press the equal-sized multiplex boards together. The bottom one sticks out in the front and the top one sticks out in the back, by the 7 cm I had marked.﻿

Joint glue is applied to the gap in the first board.﻿

An MDF board with 18 x 18 cm edge lengths helps you find the right angle. The frame is finished in just a few minutes.﻿

Now, it’s not immediately obvious why I called this pile of boards “variable.” But by the time you start working on the Duetta, it should become clear. If you need different basic dimensions for your square template, you can naturally adjust the size to your own needs. I didn’t think it was necessary to demonstrate a routing template for round cutouts – there are some very serviceable instructions online, and a little time with a search engine will quickly help you find a good suggestion.﻿